For Signals Training onsortium Use Only

Transcription

1 onsortium Use Only Inspection and Maintenance of Switches and Derails Course 202 PARTICIPANT GUIDE

2 Inspection and Maintenance of Switches and Derails Participant Guide Signals Maintenance Training Consortium COURSE 202 July 2014 Draft

3 Disclaimer: This module is intended to educate employees of transit agencies that have agreed to voluntarily participate in the Signals Maintenance Consortium. It is intended only as informal guidance on the matters addressed, and should not be relied upon as legal advice. Anyone using this document or information provided in the associated training program should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of care in any given circumstances. The Signals Consortium, it s participating agencies and labor unions, as well as the Transportation Learning Center, make no guaranty or warranty as to the accuracy or completeness of any information provided herein. The Signals Consortium, its participating agencies and labor unions, as well as the Transportation Learning Center, disclaims liability for any injury or other damages of any nature whatsoever, directly or indirectly, resulting from the use of or reliance on this document or the associated training program. Workbook Not for Distribution: For Consortium Use ONLY i

4 TABLE OF CONTENTS PAGE How to Use the Participant Guide... x MODULE 1: OVERVIEW AND SAFETY OVERVIEW SAFELY WORKING IN AN ELECTRIFIED TERRITORY SWITCH SPECIFIC SAFETY TOOLS TESTING SUMMARY MODULE 2: SWITCH AND DERAIL SPECIFIC PRINT READING OVERVIEW SWITCH AND DERAIL SPECIFIC NOMENCLATURE SWITCH AND DERAIL SPECIFIC SYMBOLS SWITCH AND DERAIL SPECIFIC RELAYS SWITCH SEQUENCE OF OPERATION SUMMARY MODULE 3: GENERAL INSPECTION & MAINTENANCE OF SWITCHES AND DERAILS OVERVIEW GENERAL INSPECTION AND MAINTENANCE LUBRICATION INSPECTING AND MAINTAINING RODS INSPECTING AND MAINTAINING CIRCUIT CONTROLLERS INSPECTING AND MAINTAINING ANCILLARY DEVICES SEASONAL INSPECTION AND MAINTENANCE TESTING INSPECTION AND MAINTENANCE CLEAN-UP SUMMARY Workbook Not for Distribution: For Consortium Use ONLY ii

5 MODULE 4: INSPECTION & MAINTENANCE OF MANUAL SWITCHES AND DERAILS OVERVIEW GENERAL INSPECTION AND MAINTENANCE LUBRICATION INSPECTING AND MAINTAINING CIRCUIT CONTROLLERS INSPECTING AND MAINTAINING ELECTRIC SWITCH LOCKS SEASONAL INSPECTION AND MAINTENANCE TESTING SUMMARY MODULE 5: INSPECTION & MAINTENANCE OF ELECTRIC SWITCHES AND DERAILS OVERVIEW GENERAL INSPECTION AND MAINTENANCE LUBRICATION INSPECTING AND MAINTAINING CIRCUIT CONTROLLERS SEASONAL INSPECTION AND MAINTENANCE TESTING SUMMARY MODULE 6: INSPECTION & MAINTENANCE OF PNEUMATIC SWITCHES AND DERAILS OVERVIEW GENERAL INSPECTION AND MAINTENANCE LUBRICATION INSPECTING AND MAINTAINING CP VALVES SEASONAL INSPECTION AND MAINTENANCE TESTING SUMMARY Workbook Not for Distribution: For Consortium Use ONLY iii

6 MODULE 7: INSPECTION & MAINTENANCE OF HYDRAULIC SWITCHES AND DERAILS OVERVIEW SENSORY INSPECTION LUBRICATION TESTING SUMMARY Workbook Not for Distribution: For Consortium Use ONLY iv

7 LIST OF FIGURES Figure 1.1 Signal Maintainer Wearing Proper PPE for Inspection and Maintenance of Switches - Courtesy SacRT... 4 Figure 1.2 Hand Throw Lever in Lever Lock Stand - Courtesy LIRR... 5 Figure 1.3 In Pavement Electro-Hydraulic Switch with Red Hand Lever in Place in Lever Box - Courtesy SacRT... 6 Figure 1.4 Switch Clamp - Courtesy SacRT... 7 Figure 1.5 Switch Clamp in Use - Courtesy SacRT... 7 Figure 1.6 Spike Against Closed Point - Courtesy LIRR... 7 Figure 1.7 Block Wedged Tightly between Open Point and Stock Rail - Courtesy LIRR... 7 Figure 1.8 The Wrong Way to Stand Near a Switch - Courtesy LIRR... 9 Figure 1.9 The Right Way to Stand Near a Switch - Courtesy LIRR... 9 Figure 1.10 Heater Wires - Courtesy LIRR Figure 1.11 Bonding Wires - Courtesy LIRR Figure 1.12 RSA Wrench - Courtesy LIRR Figure 1.13 Cup Gauge - Courtesy LIRR Figure 1.14 Spring Gauge - Courtesy LIRR Figure 1.15 Lock Rod Wrench - Courtesy LIRR Figure 1.16 Switch Crank - Courtesy LIRR Figure 1.17 Operating Wrench - Courtesy LIRR Figure 1.18 Obstruction Gauge - Courtesy LIRR Figure 1.19 Spanner Wrench - Courtesy LIRR Figure 1.20 Example Test Documentation Form - Courtesy MBTA Figure 2.1Example of a Typical Straight Line Locking Relay Circuit - Courtesy PATCO Figure 2.2 Example of a Typical Drop Line Locking Relay Circuit - Courtesy MBTA Figure 2.3 Overload Relay Represented on a Print Figure 2.4 Picture of Overload Relay - LIRR Figure 2.5 & SML represented on a print - LIRR Figure 2.6 Picture of SML - LIRR Figure 2.7 Reverse Indication Light on While Reverse Switch Repeater Relay is Energized Figure 2.8 Example Normal Configuration of an Electric Switch Figure 2.9 Example Reverse Configuration Control Circuit of an Electric Switch Figure 2.10 Example Reverse Configuration Motor Circuit of an Electric Switch Figure 2.11 Example Reverse Configuration Motor Circuit of an Electric Switch in an Overload Condition Figure 2.12 Example Reverse Configuration Indication Circuit of an Electric Switch Figure 2.13 Example of a Heater Circuit of an Electric Switch Figure 3.1 Switch Layout Highlighting Hardware to Inspect - Courtesy LIRR Figure 3.2 Insulation - Courtesy LIRR Figure 3.3 Switch Broom Bristles - Courtesy SacRT Figure 3.4 Switch Broom Scraper - Courtesy SacRT Figure 3.5 Liquefied Graphite and Graphite Brush - Courtesy LIRR Figure 3.6 Applying Graphite to a Switch Plate and Track Rod on an Open Point - Courtesy LIRR Figure 3.7 Applying Graphite to a Switch Plate on a Closed Point - Courtesy LIRR Workbook Not for Distribution: For Consortium Use ONLY v

8 Figure 3.8 Applying a Switch Plate Lubricant with a Spray Can and Applicator - Courtesy SacRT Figure 3.9 Oilet on a Circuit Controller - Courtesy LIRR Figure 3.10 Topical Application of Grease on a Motion Plate - Courtesy LIRR Figure 3.11 Application of Grease Via Grease Fitting - Courtesy LIRR Figure 3.12 Using a Rag to Tighten Coupling Between Grease Fitting and Grease Gun Nozzle - Courtesy LIRR Figure 3.13 Grease Fittings - Courtesy LIRR Figure 3.14 Close Up of a Grease Fitting - Courtesy LIRR Figure 3.15 US&S M3 with Grease to Specified Spot - Courtesy PATCO Figure 3.16 White Lithium Grease in Gearbox Coating the Gears - Courtesy LIRR Figure 3.17 Example Lubrication Inspection Sheet - Courtesy LIRR Figure 3.18 Cleaning Point Detector Bar - Courtesy LIRR Figure 3.19 Layout showing hardware to inspect - Courtesy NFTA and MBTA Figure 3.20 Locking Dogs and Drive Roller - Courtesy LIRR Figure 3.21 Lock Rods Vertical View - Courtesy LIRR Figure 3.22 Lock Rods Horizontal View - Courtesy LIRR Figure 3.23 Lock Rods Engaged with Bottom Locking Dog on Slide Bar before Switch Movement - Courtesy LIRR Figure 3.24 Lock Rods Engaged with Top Locking Dog on Slide Bar after Switch Movement - Courtesy LIRR Figure 3.25 New Lock Rod with Sharp Edges - Courtesy LIRR Figure 3.26 Old Lock Rod with Rounded Edges - Courtesy LIRR Figure 3.27 Discolored Contacts - Courtesy LIRR Figure 3.28 Pitted Contacts - Courtesy LIRR Figure 3.29 Burnt and Pitted Contact - Courtesy LIRR Figure 3.30 Contact Point of Separation - Courtesy LIRR Figure 3.31 Spring Gauge Reading - Courtesy LIRR Figure 3.32 CIL Monitor - Courtesy MBTA Figure 3.33 Circuit Controller Heater - Courtesy NFTA Figure 3.34 Movable Point Frog Diagram - Courtesy LIRR Figure 3.35 Movable Point Frog - Courtesy LIRR Figure 3.36 Locations of Switch Related Heaters - Courtesy LIRR Figure 3.37 Switch Heater Clamps - Courtesy LIRR Figure 3.38 Snow Melter Case on the Wayside - Courtesy LIRR Figure 3.39 Testing Switch Point Heater with Infrared Gun - Courtesy NFTA Figure 3.40 Testing Switch Point Heater with Spray Bottle - Courtesy NFTA Figure 3.41 Snow Covers - Courtesy MBTA Figure 3.42 Metal Basket Covers - Courtesy LIRR Figure 3.43 Clothe Basket Covers - Courtesy LIRR Figure 3.44 Appropriately Loosened Lock Rod Hardware - Courtesy LIRR Figure 3.45 Prying Point Open using a Operating Rod Wrench - Courtesy LIRR Figure 3.46 Adjusting Point Tension - Courtesy LIRR Figure 3.47 Point Detector Rod in Context of the Switch Layout - Courtesy LIRR Figure 3.48 Point Detector Rod in Context of the Circuit Controller - Courtesy LIRR Figure 3.49 Initial Check with Feeler Gauge between Roller and Bevel - Courtesy LIRR Workbook Not for Distribution: For Consortium Use ONLY vi

9 Figure 3.50 Cup Gauge in Place at Far Point and Reverse Indication Contacts Open - Courtesy LIRR Figure 3.51 Cup Gauge in Place at Near Point and Reverse Indication Contacts Open - Courtesy LIRR Figure 3.52 Obstruction Gauge in Place on a Switch - Courtesy LIRR Figure 3.53 Obstruction Gauge in Place on a Lifting Block Derail - Courtesy LIRR Figure 4.1 US&S T-21 Switch Machine - Courtesy LIRR Figure 4.2 U5 Auxiliary Circuit Controller - Courtesy SacRT Figure 4.3 W100 Auxiliary Circuit Controller Figure 4.4 Spring Switch - Courtesy SacRT Figure 4.5 Diagram of a Spring Switch - Courtesy SacRT Figure 4.6 High Target Staff Bearing - Courtesy MBTA Figure 4.7 Target Bearing Location on T-20 - Courtesy MBTA Figure Lubrication Inspection Sheet for a US&S T-21 Switch Figure 4.9 Pitted Contact - Courtesy LIRR Figure 4.10 Return Spring on an Auxiliary Circuit Controller - US&S Figure 4.11 U5 Circuit Controller Illustrating Clamp and Adjusting Screw - US&S Figure 4.12 Bolt and Ball Stud on Operating Crank Figure 4.13 Closed Circuit Controller Box with Padlock in Place on a Low Profile Electric Lock - Courtesy LIRR Figure 4.14 Electrical Locking on a Manual Switch on a Low Profile Electric Lock - Courtesy LIRR Figure 4.15 Alstom 9B Electric Lock High Stand in Context in a Lab Setting Courtesy METRA Figure 4.16 Alstom 9B Electric Lock High Stand Control Panel Courtesy METRA Figure 4.17 Alstom 9B Electric Lock High Stand Control Panel - Courtesy METRA Figure 4.18 Alcohol Bottle - Courtesy LIRR Figure 5.1 Safely Removing Cover of a 5F - Courtesy MBTA Figure 5.2 Moving Cutout Switch Mechanism to Cutout Position - Courtesy SacRT Figure 5.3 Plexiglass Commutator Cover on 5E Machine - Courtesy NFTA Figure 5.4 Permanent Magnet Type Motor- Courtesy MBTA Figure 5.5 Pinched Wire - Courtesy MBTA Figure 5.6 AAR Terminals and Wiring in Good Condition on an M23 Switch Machine - Courtesy MBTA Figure 5.7 Terminals and Wiring in Good Condition on GRS 5F - Courtesy MBTA Figure 5.8 Areas on a GRS 5E Commutator to Clean - Courtesy NFTA and MBTA Figure 5.9 M23 Motor Compartment Labeling Main Components - Courtesy MBTA Figure 5.10 M23 Commutator and Brushes Illustrating Beveled Edge - Courtesy MBTA Figure 5.11 Commutator and Brushes on M23A in Good Condition - Courtesy MBTA Figure 5.12 Commutator and Brushes on GRS 5F in Good Condition - Courtesy MBTA Figure 5.13 End of Clutch on M23 - Courtesy MBTA Figure 5.14 Diagram GRS 5 Series Detent - Courtesy NFTA Figure 5.15 GRS 5 Series Detent - Courtesy NFTA Figure 5.16 M23 and 5F Comparison Highlighting Motor Compartment, Gear Compartment and Circuit Controller - Courtesy MBTA Figure 5.17 Oilet on a M23 Circuit Controller - Courtesy LIRR Workbook Not for Distribution: For Consortium Use ONLY vii

10 Figure 5.18 Diagram of Point Detector Contact Yoke on a Model 5 - Courtesy NFTA Figure 5.19 Picture of a Point Detector Contact Yoke on a Model 5- Courtesy MBTA Figure 5.20 M23-A Circuit Controller Shaft Assembly - Courtesy MBTA Figure 5.21 Brush Arm Pivot Point on a GRS Switch Machine - Courtesy LIRR Figure 5.22 Oiling Crank Cutout Linkage on a 5E - Courtesy NFTA Figure 5.23 Selector Lever Cutout Linkage on GRS 5F - Courtesy MBTA Figure 5.24 Diagram of Motor and Indication Cutout Contacts Linkages on a M23 - Courtesy MBTA Figure 5.25 Oil Location Specific to GRS 5 Series - Courtesy MBTA Figure 5.26 Clutch Shifter Mechanism on a 5F Machine - MBTA Figure 5.27 Clutch Shifter Mechanism Lubrication Points on a 5F Machine - Courtesy MBTA Figure 5.28 Lubrication Inspection Sheet for a US&S M23 Switch - Courtesy LIRR Figure 5.29 GRS 5 Series Specific Oiling Points- Courtesy MBTA Figure F Circuit Controller Highlight Key Components - Courtesy MBTA Figure 5.31 AAR Terminals on an M23 Switch Machine - Courtesy MBTA Figure 5.32 AAR Terminals on a GRS 5F - Courtesy MBTA Figure 5.33 Shunt Straps on a 5F - Courtesy MBTA Figure 5.34 H-Bars - Courtesy MBTA Figure 5.35 Close-up of U-Shaped Spring on 5 Series - Courtesy MBTA Figure 5.36 Snub Rectifier and Thermal Resistive Snub Wire in GRS 5 Series Circuit Controller Compartment - Courtesy NFTA Figure 5.37 Snub Rectifier on a Series VDC Switch Machine - Courtesy MBTA Figure 5.38 Placing Clamp On Amp Meter for Overload Test - Courtesy LIRR Figure 5.39 Amperage Reading Taken by way of Analog Meter - Courtesy PATCO Figure 5.40 Wedging Clutch Housing to Prevent Movement - Courtesy MBTA Figure E Clutch Mechanism Highlighting Clutch Adjusting Nut, Locknut and Setscrew - Courtesy NFTA Figure E Clutch Mechanism Highlighting Hand crank and 5/16 Inch Diameter Pin - Courtesy NFTA Figure 6.1 Basic Components of an A-5 Electro-Pneumatic Switch - Courtesy LIRR Figure.6.2 Compressor Air Lines/Hoses are a Tripping Hazard - Courtesy LIRR Figure.6.3 NEVER Put Foot on Baseplate of a Pneumatic Switch/Derail - Courtesy LIRR Figure.6.4 Spanner Wrench Ensuring a Tight Cylinder Plug - Courtesy LIRR Figure.6.5 Deteriorated Air Hose/Line - Courtesy LIRR Figure.6.6 Dripping Oil onto Air Cylinder Piston Rod - Courtesy LIRR Figure.6.7 Smearing Oil using a Lint free shop towel - Courtesy LIRR Figure.6.8 Piston in Proper Position for Lubrication - Courtesy LIRR Figure.6.9 Piston in Wrong Position for Lubrication - Courtesy LIRR Figure.6.10 Greasing Walking Beam Shaft - Courtesy LIRR Figure.6.11 Removing Shifting Piston - Courtesy LIRR Figure.6.12 Applying New Grease - Courtesy LIRR Figure.6.13 A-5 Electro-Pneumatic Lubrication Inspection Sheet - Courtesy LIRR Figure.6.14 Exploded View of a CP Valve - Courtesy LIRR Figure.6.15 Valve Magnet Highlighting Armature Stem and Helper Spring - Courtesy LIRR 153 Figure.6.16 Using Operating Wrench to Simulate Creepage of Slide Bar - Courtesy LIRR Workbook Not for Distribution: For Consortium Use ONLY viii

11 Figure.6.17 Voltmeter on Indication Contacts for Switch Restoring Circuit Test - Courtesy LIRR Figure 6.18 Walking Beam at Center State During Minute Man Test - Courtesy LIRR Figure 6.19 Covers and Lock Magnet Valve Stem Removed - Courtesy LIRR Figure.6.20 Turning Off Globe Valve to Prepare for Switch and Valve Non-Correspondence Test - Courtesy LIRR Figure.6.21 Removing Plug From Reverse Side of Air Cylinder to Prepare for Switch and Valve Non-Correspondence Test - Courtesy LIRR Figure 7.1 Diagram of Pressure Measuring Points on H&K Switch - Courtesy SacRT Figure 7.2 Picture of H&K Switch Highlighting Pressure Measuring Points - Courtesy SacRT Figure 7.3 Electrical Connections on an H&K - Courtesy SacRT Figure 7.4 Lubrication Points - Courtesy SacRT Workbook Not for Distribution: For Consortium Use ONLY ix

12 How to Use the Participant Guide Purpose of the Course The purpose of the Inspection and Maintenance of Switches and Derails course is to assist the participant in demonstrating safe inspection and maintenance of switches, derails, and their associated components. Approach of the Book Each course module begins with an outline, a statement of purpose and objectives, and a list of key terms. The outline will discuss the main topics to be addressed in the module. A list of key terms identifies important terminology that will be introduced in this module. Learning objectives define the basic skills, knowledge, and abilities course participants should be able to demonstrate to show that they have learned the material presented in the module. A list of key terms identifies important terminology that will be introduced in each course module. Review exercises conclude each module to assist the participants in reviewing key information. Workbook Not for Distribution: For Consortium Use ONLY x

13 MODULE 1: Overview and Safety Module 1 Outline 1-1 Overview 1-2 Safely Working in an Electrified Territory 1-3 Switch and Derail Safety 1-4 Tools 1-5 Testing 1-6 Summary Purpose and Objectives: OVERVIEW AND SAFETY The purpose of this module is to provide the participant with an overview on how to safely inspect and maintain switches and derails. Following the completion of this module, the participant should be able to complete the exercises with an accuracy of 70% or greater: Identify trip, slip and fall hazards related to inspection and maintenance of switches and derails Identify pinch points related to inspection and maintenance of switches and derails Describe how to manually throw a switch Demonstrate ability to utilize secondary protection in order to stop switch from being thrown Describe procedures for working in electrified territory Identify proper PPE to be used during inspection and maintenance of switches and derails Identify and describe tools specific to inspection and maintenance of switches and derails List Tests Mandated by the FRA List pertinent timing for each test (monthly, quarterly, etc) as per your authority Demonstrate ability to complete proper documentation Key Terms 30 amp Current Meter Capacitors Cup Gauge Feeler Gauge Hand Position Insulation Job Briefing Meeting Lock Rod Wrench Lockout-Tagout Minute-Man Test Motor Overload Test Motor Position Obstruction Gauge Obstruction Test Operating Wrench Personal Protective Equipment (PPE) Pinch Points Point Detector Test Point Tension Test Road Worker in Charge RSA/AAR/Raco Wrench Selector Lever Switch Block And Spike Switch Crank Switch Lock Switch Restoring Circuit Test Switch Clamp Third Rail Time On The Line Trip, Slip, And Fall Hazards Workbook Not for Distribution: For Consortium Use ONLY 1

14 MODULE 1: Overview and Safety Securing the Area Table 1 Securing the Work Area Before Switch Inspection and Maintenance Manual Electric Electro-Pneumatic Electro-Hydraulic Request Time on Line X X X X Disconnect X X X Indication/Motor Power Secure Points X X X X Shut-off Pneumatic Valve X As with most inspection and maintenance of signals, it is important to always make sure that your first step is to request time on the line. This means that dispatchers know that you are in the field and will not route any trains in your direction until time is removed or the RWIC gives permission If the switch is electric and power is not needed, disconnect power to the motor. This can be done either by using the hand throw selector lever, if equipped. Otherwise, power can be removed by inserting the hand crank. This will prevent the possibility of the switch being thrown remotely. For electrical, throw the switch into manual. This will be done differently depending on the specific switch. As illustrated in the video below, for a US&S M23, start by first removing the switch lock which is located at the hand throw lever (which is located at the lever lock stand - see Figure 1.2). Next, step on the pedal. Now the selector lever is free to be moved. Move the selector lever from the motor position to the hand position. Figure 1.2 Hand Throw Lever in Lever Lock Stand Workbook Not for Distribution: For Consortium Use ONLY 5

15 MODULE 1: Overview and Safety For electrical switches without hand throw ability, insert a hand crank which will open the crank contacts to switch, removing motor and in some instances indication power. If neither application is available remove power in the signal case by turning off breaker or removing the power fuse to the individual switch/s your are working on. See Video 1.1 Putting Switch into Hand Throw for an illustration on how to put an electrical switch into hand throw ( For electro-pneumatic switches and derails, use the shut off valve to remove pneumatic pressure (air) - unless it is needed for the inspection/maintenance to be performed. For in-pavement electro-hydraulic switches and derails, insert the hand throw lever into the lever box. At this point, the hand throw lever energizes the lever box proximity sensor, which deenergizes the motor and detector circuits. The switch can then be manually operated via the hand throw lever with a single stroke. Figure 1.3 In Pavement Electro-Hydraulic Switch with Red Hand Lever in Place in Lever Box - If it is not possible to remove power but the point will not need to be moved, the point should be secured using either a switch clamp or switch block and spike in order to diminish the chance of getting body parts pinched in the switch. Note that permissions may be required from dispatcher/center to block/clamp and spike the switch. Always follow your authority's procedures. Workbook Not for Distribution: For Consortium Use ONLY 6

16 MODULE 1: Overview and Safety Figure 1.4 Switch Clamp Figure 1.5 Switch Clamp in Use For the switch clamp, clamp the point against the rail as close to the end of the point as possible. If the switch will be out of service for a long period of time, a switch clamp with a lock (Figure 1.4 and Figure 1.5) may be used. As always, follow your authorities procedures. Figure 1.6 Spike Against Closed Point Figure 1.7 Block Wedged Tightly between Open Point and Stock Rail When using the switch block and spike technique, a standard wood wedge will be put in the open point, pushed back until it is tight against the stock rail. A spike will be placed through the tie plate tight against the closed point. Workbook Not for Distribution: For Consortium Use ONLY 7

17 INSPECTION AND MAINTENANCE OF SWITCHES AND DERAILS MODULE 2: Switch and Derail Specific Print Reading Module 2 Outline SWITCH AND DERAIL SPECIFIC PRINT READING 2-1 Overview 2-2 Switch and Derail Specific Nomenclature 2-3 Switch and Derail Specific Symbols 2-4 Switch and Derail Specific Relays 2-5 Switch and Derail Sequence of Operation 2-6 Summary Purpose and Objectives: The purpose of this module is to provide an overview of the specific nomenclature and relays used in railroad switch and derail systems and how they form the operation of railroad switches and derails. Following the completion of this module, the participant should be able to complete the exercises with an accuracy of 70% or greater: List switch and derail specific nomenclature List switch and derail specific relays and describe their functions Using a print, describe the sequence of operation for an M3 single ended switch Demonstrate ability to outline the sequence of operation of a single-ended switch Key Terms Call Clutch Control Circuit Correspondence Crank Cut-out Contact Field Wires Hand Crank Heater Circuit Indication Circuit Indicator Lock Lock Relay Motor Circuit Normal Normal Configuration Overload Coil Overload Relays o Stick Coil o Operation Coil Position Relay Reverse Reverse Configuration Shunting Strip Switch Control Relay (WR) Switch Machine Lock (SML) Switch Related Component Switch Repeater Relay Workbook Not for Distribution: For Consortium Use ONLY 17

18 INSPECTION AND MAINTENANCE OF SWITCHES AND DERAILS MODULE 2: Switch and Derail Specific Print Reading Table 3 Other Switch and Derail Specific Nomenclature (*Source: AREMA volume 4 page 208) Abbreviation Item* AREMA* Your Location Switch operating mechanism or lock valve W Relay, controller or contactor controlling both normal and reverse operations of a switch or an electric switch lock WR Relay, controller or contactor controlling the normal operation of a switch or an electric switch lock NWR Relay, controller or contactor controlling the reverse operation of a switch or an electric switch lock RWR Relay repeating WR WRPR Relay repeating position of switch WPR Relay repeating normal position of switch or normal NWPR position of WPR Relay repeating reverse position of switch or normal RWPR position of WPR Indicator of the positions of a switch WK Switch and derail lock operating mechanism on a switch WL Relay repeating normal position of a switch lock NWLPR Relay repeating normal position of a dual-control lever NJPR Relay repeating reverse position of dual-control lever RJPR Indicator of the normal position of a switch NWK Indicator of the reverse position of a switch RWK Indicator of the block condition in approach to a switch WAK Relay repeating reverse position of a switch lock RWLPR Normal Switch Correspondence Relay NWCR Reverse Switch Correspondence Relay RWCR Spring Switch SS Lock Relay LR Reverse Switch Request Relay RWZR Normal Switch Request Relay NWZR Restore to Normal Request Relay R-NWZR Workbook Not for Distribution: For Consortium Use ONLY 19 Notes

19 INSPECTION AND MAINTENANCE OF SWITCHES AND DERAILS MODULE 2: Switch and Derail Specific Print Reading Figure 2.9 Example Reverse Configuration Control Circuit of an Electric Switch Workbook Not for Distribution: For Consortium Use ONLY 28

20 Module 3 Outline COURSE 202: INSPECTION AND MAINTENANCE OF SWITCHES AND DERAILS MODULE 3: General Inspection & Maintenance of Switches and Derails 3-1 Overview 3-2 General Inspection and Maintenance 3-3 Lubrication 3-4 Inspecting and Maintaining Rods 3-5 Inspecting and Maintaining Circuit Controllers 3-6 Inspecting and Maintaining Ancillary Parts 3-7 Seasonal Inspection and Maintenance 3-8 Testing 3-9 Inspection and Maintenance Cleanup 3-10 Summary GENERAL INSPECTION & MAINTENANCE OF SWITCHES AND DERAILS Purpose and Objectives: The purpose of this module is to provide an overview of the inspection, maintenance and testing that is performed on all types of switches. More specific details for different types of switches will be covered in the following modules. Following the completion of this module, the participant should be able to complete the exercises with an accuracy of 70% or greater: Identify hardware which needs to be tightened Demonstrate ability to tighten appropriate hardware Ensure all locks are in place and secure Identify areas/components which need to be lubricated on a regular PM schedule Inspect and maintain switch layout (where applicable) Describe purpose and components of mechanical locking Inspect and maintain lock rod Inspect and maintain throw rod Inspect and maintain point detector rod Inspect and maintain switch circuit controller Inspect and maintain switch point heaters/snow melters (where applicable) Inspect and maintain moveable point frogs Demonstrate ability to perform point detector test Demonstrate ability to perform obstruction test Demonstrate ability to adjust point tension Inspect and maintain circuit control heaters (where applicable) Demonstrate ability to test electrical indication Workbook Not for Distribution: For Consortium Use ONLY 35

21 MODULE 3: General Inspection & Maintenance of Switches and Derails 3-2 GENERAL INSPECTION AND MAINTENANCE The first step in doing any inspection and maintenance is to perform a sensory inspection. For switches and derails this includes walking the length of the layout, both inside and outside, to make sure that all hardware is in place, clean and secure. Hardware that should be checked include nuts, bolts, ties, points, derails, etc. One visual sign that may indicate that hardware is not secure is the presence of rust around that hardware. Pay special attention looking for items that would inhibit smooth movement of the switch point and/or hang the switch up. The majority of hardware to check are nuts and bolts. These are found on operating rod, track rods, lock rods, point detector rods, yoke and on switch mounting bolts (on all four corners). Hardware to check include: Nuts and bolts Switch Heater Terminations Bonding Ground Wires Switch keeper* also known as Lock Stand Track braces* Plates* Stock Rail Spikes/Screw Spikes* Electro-Hydraulic Difference: do not inspect/maintain the following: Switch Keeper Plates Track Braces Stock Rail Spikes/Screw Spikes Figure 3.1 Switch Layout Highlighting Hardware to Inspect - Courtesy LIRR Workbook Not for Distribution: For Consortium Use ONLY 39

22 MODULE 3: General Inspection & Maintenance of Switches and Derails An operating rod wrench or pry bar is used to make sure that the point or derail is tight against the stock rail. Next, the switch should be thrown. Notice any excessive movement of the tie plates, ties, stock rail or the switch machine itself. Additionally, make sure all appropriate locks are in place and secure. Generally, the locks that should be in place include the keeper lock also known as the throw lock, circuit controller lock,, gear compartment locks, two motor locks and a junction box lock, if equipped. Make sure to tighten any lose hardware and replace any pieces that are missing. Table 7 Generic Sensory Inspection of Switches and Derails Sense Example Problems Sight Debris, dirt, clutter, untamped ballast, rotting, instabilities, rust, worn insulation, lubricant outside the gearbox, proper drainage, hairline damage or distortion to case, cover and/or other structural components, breaks/weak points or any other signs of physical damage. Smell Burning Touch loose points, hardware, etc Hear Grinding, clanging sound, loose or broken parts During this walkthrough, perform a visual inspection of switch rod and gauge plate insulation. Worn/deteriorated insulation will not only disrupt the track circuit but can also affect the integrity/alignment of the switch layout. This may be a problem the day of inspection or in the future if further deterioration occurs. If insulation is worn and/or deteriorating, notify the correct personnel in charge so that it will be replaced as soon as possible. Deteriorating Insulation Insulation is in Good Condition Figure 3.2 Insulation - Courtesy LIRR Workbook Not for Distribution: For Consortium Use ONLY 40